Process of making connectors



. H. B. SHERMAN. PROCESS OF MAKING CONNECTORS. APPLlCATlON FILED MAY 2!, I9l9. RENEWED JUNE 28,1920.

1,352,034. PatentedSept. 7,1920.

F i 5 0-: G L e: L A A /Z (Q' (Q LC,

Qwbewboz PATENT OFFICE).

HOWARD B. SHERMAN, OF BATTLE CREEK, MICHIGAN.

PROCESS OF MAKING CONNECTORS.

Specification of Letters Patent.

Patented Sept. 7, 1920..

Application filed May 21, 1919, Serial No. 298,778. Renewed June 28, 1920. Serial No. 392,519.

exact description thereof, reference being had to the accompanying drawings, which form part of this specification.

This invention is a novel process of making novel connectors employed for connecting electrical wires.

The usual connector is a short metal sleeve and the wires from an electrical fixtureare entered into one end of such sleeve and secured by a screw; and the end of the electrical supply wire is similarly connected to the other end of the sleeve by a similar screw. There may be a multiple of wires in the fixture, all of which are usually of the same gage, and the ends of such wires are entered into the same end of the sleeve and must be confined therein by the same screw. It is necessary to use separate set screws for the fixture wires and supply wires, because if the fixture wires and supply wires were of different gage one set screw could not properly secure them, because the smaller wire or wires would not be pinched or seated by such screw, as the larger wire would prevent the smaller wire being properly pinched by the screw. The said sleeve is also usually provided with some internal means, between the two set screws, to prevent wires inserted in one end of the sleeve projecting beneath the screw at the opposite end, which if the wires were not equal in diameter would cause the same difficulties which would arise if only one set screw were used.

These sleeve connectors are usually small and the screws very short, and therefore liable to be lost by being unscrewed too far in preparing the connector for engagement with the wires; as in backing out the screws -to get ready to put in the wires, the workmen frequently withdraw the screws too far and they drop out; and being very short and small, if they drop out they are apt to be lost, or, at least, cause considerable annoyance and loss of time in searching for them. To prevent these annoyances the connectors have sometimes been provided with means for preventing loss of the screws.

The object of the present invention is to make a simple and inexpensive sleeve connector by a novel method or process, such connector being so formed that both the fixture wires and the supply wire can be readily connected therewith and prevented from overlapping or passing each other, so that the screws will properly pinch the wires intended to be secured thereby; and the screws be securely -retained in place in the connector.

The invention has particular reference to the method of making such connector which I will now explain in connection .with the accompanying drawings which illustrate a novel connector and the process of making same, and-will enable others to readily understand, adapt and use the invention; and I refer to the claims following the descrip tion for concise statements of the novel essentials of the invention for which protection is desired.

In said drawings:

Figure '1 is a perspective view of a complete connector.

Fig. 2 is a longitudinal sectional view thereof showing the wires attached.

Fig. 3 is a plan view of a blank for ing such connector after it has been initially cut and pressed.

Fig. 4: is an enlarged end view showing such blank partially folded.

Fig. 5 is a similar view showing a screw positioned in the blank.

Fig. 6 is an end view showing the completion of the folding operations.

Figs. 7 and 8 are longitudinal sectionaviews showing slight modifications of partition.

The main body 1 of the connector is preferably formed out of a strip or blank of sheet metal, such as brass, so that it will be an excellent conductor. The blank is bent into a tube or sleeve, preferably substantially rectangular in cross section.

The size and cross sectional conformation of the body however is not restricted to the particular form shown in the drawings.

The blank is preferably so bent that top a and side portions 6, b are solid but the two end portions 0, c are bent to form the bottom portion, such bottom blank having longitudinal slit formed, as indicated at col/- the between the meeting ends of the parts a, "c from the metal or thereafter, at the proper of the blank strip.v point, with the pressed partition forming [In the top portion a of the blank 1 is portions 1", 1 or 1. The blank isthereafter pressed apreferably centrally disposed transbent along the dotted lines a, b, c (Fig. 3) 5 verse rib 1", whi h is preferablyformed by by means of a suitable forming machine, or 70 pressing the st so as to form a rib 1 by a'suitable press, not shown, until the side therein, which rib when the blank is folded {portions 6, b are at an angle of about 90 to will lie within the inner face of the top of thetop portion a, while preferably the bot-* the body, and bejcentrally disposed thereof tom portions c are bent'at an angle of about when the blank is bent into tubular shape, 45 to theparts b, b; but sufiicient space is 75 i the rib leaving a corresponding depression left between the extremities of the parts 0 in the outer face of the top. for the insertion of the headed screws 2; In the opposite end portions 0, 0 of the which may then be engaged with the threadblank may be similarly pressed shortribs 1 ed openings 1?, as indicated in Fig. 5; and which when the blank is folded to form the thereafter by suitable means the folding of 30 body meet and together form an inwardly the blank into'the shell or tubular form is projecting transverse rib corresponding in completed, as indicated in Fig. 6. lengthand contour to rib 1 and meeting While this is the preferred method of maktherewith. The ribs'l 1 when the blank is ing the connector so as to inclose and retain properly bent to form the body to ether conthe headed screws, I do not consider the in- 5 stitute an internal partition exten ing across vention restricted to the particular sequence the inner space of the body and substantially of steps .recited. For example, it would be closing same, so thatthe wires (w, 'w) inpossible after stamping out the blank to inserted in either end of the body will be sert. the screws 2 andthem fold in the side stopped by such partition (see Fig. '2) and portions 6 and bottom 0 ions 0. Or the cannot be assed through the body. If de: -side portions 12 might be olded to approxisired the ri s 1 might be omitted and the rib mate position; then "the screws 2 inserted; 1 made dee enough to form the partition; and then the bottom-parts c folded. Or the or instead 0 these ribs 1", 1 the top a'might parts c might be first folded relative to the '30 be centrally slitted and the ends of the slit parts I) then the screws 2 inserted, then the bent inward to form a tongue or tongues sides I) folded to complete the tube. v 1", 1' as in Fig. 7, such tongue or tongues The essential steps of the novel method of serving as the partition; or the to may have "making the connector are: cutting the short integral bent parts 1, 1 in place of proper blank; provi ing the threaded open 85 ribs 1) and the bottom portions have short ings therein; enga f g the screws with the integraLbent in parts 1 1 (in place of ribs openings andfinal y. folding'or completing .1) which parts 1, 1 when the blank isfoldthe folding-of the blank so as to inclos'e the ed form a partition, as shown in Fig. 8. headed portions of the screws and thus re- It will be 'seen that such 'a blank 1, for tain the screws permanently in position in 40 forming the body, of the connector can be the connector.

, readily stamped out ofsheet metal, with the What I claim Q portions 1", 1 or 1 pressed therein, and be 1. In the process of making a tubular conafterward bent into box or tube form as nector provided with screws; forming a shown in F 1 and 6. blank provided with suitable threaded open- 45 In the part a of the body forming the top ings; engaging screws with the said threadof the connector are formed screw threaded ed openings; and then completing the foldopenings 1' at. opposite sides of, the parti ing oftheblank into tubular form to permation; and each opening is en 'aged'by ascrew nentl retain the screws in the connector. which (asshown) is prefera 1 provided on 2. he process of making a connector of 50its inner end with an enlarged ead or flan e the character specified, consisting in formg 2"' that preferably snugly' fits between t e ing a suitable blank to make a tube of the. s'idewalls b, b of the complete body andwill desired size, inserting screws having flanged preventany. wires (w, 'w' Jinserted therein or headed inner ends in the blank, and compa or squeezing beside such screw when 'pleting the folding ofthe blank to form a 55' 317-18 0. ampedthereom-and insures thatall. tube. 1

- the wires inserted under suchscrewwill be 5 '3. The method of making a connector of enga d and held thereby when the screw is the character specified, consisting in formrun own. The screw head 2P-also prevents ing-a suitable blank tomake a tube ofthe the screw from being backed out ofthe condesired size, 'provi it with. threaded. 60 nector and lost. e I I The preferred method orprocess of makshape, insert .fla'nged or headed screws in in such-connectors'is as-follows: the blank; an completing the folding, of I he blank -l of be proper. size, indicated the blank to form a tubeinclosing the heads in Fig. .3, is stamped orcut from sheet metal ofthe screw s. i 65 and may be provided atthe time it is cut 4. The method of forming .a connector, 130

openings; partly folding said'blank -i1ito such manner that when the blank is folded.

such part or parts will produce an internal partition within the connector.

' providing such blank with threaded holes 5.The method of forming a connector,

consisting in cutting a blank of the desired width and length to form a tubular sleeve when folded, and pressing integral part or parts of the blank relative to the body thereof in such manner that when the blank is folded into a tube such part or parts will produce an internal partition within the connector, and providing said blank with suitable threaded openings which when the blank is folded will lie at opposite sides of the partition formed by said portions. v

6. The method of forming a tubular electrical connector consisting in cutting a metal blank of the proper width and length; and

for the reception of screws; partially folding the sides and ends of said blank to form the sides and bottom of the tube when the is completed; inserting in the threaded openings headed or flanged screws; then completing the folding of the sides and ends of the blanks so as to inclose the heads or flanges of the screws within the tube.

7. The method of forming a connector, consisting in cutting a blank of the desired width and length to form a tubular sleeve when folded, and pressing in said blank an integral portion or portions which when the blank is folded will produce an internal partition within the connector; forming threaded openings in the blank which when the blank is folded will lie at opposite sides of the partition; inserting in the threaded openings headed or flanged screws, then folding the blank so as to inclose the heads or flanged ends of the screws within the connector, substantially as described.

8. The method of forming a connector, consisting in cutting a blank of the desired width and length to form a tubular sleeve when folded, and pressing in said blank an integral portion or portions which when the blank 'is folded will produce an internal partition within the connector; forming threaded openings in the blankwhich when the blank is folded will lie .at opposite sides of the partition; partially folding the sides and ends of said blank to form the sides and bottom of the connector when the folding is completed; inserting in the threaded open ings headed or flanged screws; then completing the folding of the sides and ends of the blank so as to inclose the heads or flanged ends of the screws within the connector, substantially as described.

In testimony that I claim the foregoing as my own, I aflix my signature.

HOWARD B. SHERMAN. 

